Anda di halaman 1dari 7

INSTRUMENTATION FOR EQUIPMENT PACKAGES

The test program shall be designed to prove that the following aspects of the instrument and electrical
equipment/system are satisfactory:
Installation.
Integrity.
Calibration.
Operation.
The following equipment shall be tested:
Electrical equipment.
Instruments.
Panels.
Cable.
Impulse line tests.
The CONTRACTOR's Inspector shall perform the following inspection checks, as required:
Verify against approved documents that all items have been supplied and installed correctly.
Check tagging and location of equipment for accessibility for operation and maintenance.
Check appearance, paintwork, dimensions and fixing points against final agreed drawings.
Check routing and segregation of all cabling.
Verify that all wiring, cables and cores are correctly terminated and that cable / terminal markers
and nameplates correspond to the documentation.
Verify that calibration certificates, material certificates and hazardous area certification for all
applicable instrumentation equipment are available in accordance with project specifications and
requirements.
Verify that welding and NDT has been performed using CONTRACTOR approved procedures and
NDT reports properly reviewed and endorsed by qualified NDT Interpretation personnel.
Verify that hydrostatic pressure test certificates / certification for all applicable instrumentation
equipment, including impulse lines, are available in accordance with project specifications and
requirements.
The following list applies to the testing:
Wiring shall be tested for continuity and insulation. The test voltage shall be compatible with the
wiring being tested.
Instrument air systems shall be checked for leaks using dry air at a pressure 110% of maximum
working pressure.
Impulse lines shall be disconnected from both the process line and the instrument, and
hydraulically tested to 1.5 times process line design pressure. Instrument equipment and piping
shall be thoroughly flushed and dried on completion of test.
After installation, instruments shall be calibrated and demonstrated to be within VENDOR
specification.
If necessary, VENDOR shall arrange for the instrument manufacturer representatives to perform
the calibration and test.
Certificates of test for electrical components, instruments, and associated equipment shall be
available.
Test certificates shall state values for test results unless cross-referred to test procedures giving
test criteria.
The following activities shall be carried out as part of the FAT only where the tests have not already
previously been completed:
Verification of physical interconnections between systems,
Communication checks between systems,
Verification of data transfer between applications,
Redundancy checks (If appropriate),
Functional checks of data interfaces between package and ICSS,
Failure mode performance tests.
System backup and restore, including disaster recovery.

19.9.1. Hardware Inspection and Testing


All package equipment shall be inspected and tested with respect to the following:
Hardware verification against approved drawings and schedules.
Visual inspections and safety checks
Earthing checks
Power system checks
Power supply redundancy tests
EMI / RFI tests
I/O point-to-point tests
Hardwired I/O function tests
FF I/O function tests. As a minimum each segment (port), including spares, shall be operationally
tested by live connection of at least one Fieldbus device. The Fieldbus device shall be connected to
the terminal block designated for the field wiring or system cable.
HART I/O function tests
Cabinet Alarms function tests
Failure and recovery of redundant modules except where redundancy is a built in feature of the
system and does not rely on software configuration.
Battery Backup tests
Black start recovery tests
Online replacement tests
ATEX requirements

5 ELECTRICAL EQUIPMENT SELECTION AND INSTALLATION


5.1 LAYOUT
Electrical apparatus shall be located in such a manner as to enable ease of maintenance when
in service.
Location of electrical equipment within the package unit shall ensure adequate access for
cabling and routing and shall be detailed on VENDORs drawings.
VENDORs shall provide space on cable tray or racking for cables within package unit
boundaries.
Items requiring external cable connections shall be located on perimeter of packaged skid
(unless a direct connection to equipment within the package is more convenient for installation
and for maintenance).
Installation shall also satisfy all relevant statutory and regulatory requirements applicable at the
installation site.
Adequate space shall be left between gland plates and terminal strips to ensure termination of
each cable is practicable once all other cables have been terminated.
Protection shall be provided for cables, electrical equipment, devices, and conduits when
installed in areas subject to physical damage or vibration. Protection shall also be provided to
protect cables, electrical equipment and conduit from damage during fabrication.
Electrical equipment shall be installed in a neat manner. Trays, channels and cables shall be
routed horizontally and vertically, parallel to one another or at right angles to equipment line.
Working space around equipment shall as a minimum, be in accordance with manufacturers
recommendations. Sufficient aisle space shall be provided to allow for the removal of
equipment.
Control panels or local controls shall be constructed and sited to prevent physical damage or
inadvertent operation.
Details of possible future extensions shall be provided. The VENDOR shall make allowance for
these extensions when planning the layout.
Motors or generators shall not be mounted in a position where airflow is obstructed or where the
hot air discharge of one machine is directed at the air intake of another.
Conduits shall be arranged to allow for low point drains.
5.2.1 Certified Equipment Register
The VENDOR shall provide copies of Hazardous Area Certificates of Compliance for all equipment
supplied for installation in hazardous areas. A Schedule of Electrical Equipment in Hazardous Areas,
showing the full details of the equipment and statutory approvals shall be provided. At a minimum,

the schedule shall include the following information:


Item/Tag No.
Service Description
Manufacturer
Model No.
Ex Marking
Certifying Authority
Certificate Number
Expiry Date
Area Classification
IP Rating
Tests shall include:
a) Test cables (IR and continuity) after cables have been glanded to equipment with cores
isolated.
b) Megger motor windings and transformer windings.
c) If evidence of moisture accumulation is found, equipment must be dried out and re tested
before operation.
d) Check circuit breakers, motor starters, switches, relays and other equipment for loose

connections (both mechanical and electrical) to see that contacts and working parts are
correctly aligned and free from dust and foreign matter.
e) Check motors for proper rotation, lubrication and proper alignment.
f) Perform operational tests on motor control circuits.
g) Perform operational tests on control switches, alarm and shutdown devices, indicating
lights and meters for proper operation.
h) On circuit breakers with adjustable trips, check both thermal and magnetic settings for
proper protection.
i) Check protection relay settings and perform injection tests.
j) Earthing/grounding tests (both continuity and impedance) shall be carried out and results
recorded.
Certificates of Test shall be provided for each item of electrical apparatus to prove it has been
satisfactorily tested to meet requirements of its appropriate manufacturing standards, whether or
not witnessed.
If appropriate, test certificates shall state values for test results.
Test certificates for tests witnessed by contractor shall be available for signature on day of test.
Test instruments shall be an approved type and calibrated against certified standards or
standard instruments at regular and proper intervals, and their accuracy must be fully
substantiated at time of tests.
All electrical equipment and installations specified to operate in a hazardous area shall comply
with requirements of IEV 60079-14 and IEC 60079-17. Suppliers of such equipment /
installations shall provide the following documentation as a minimum to verify the integrity of the
installation and compliance with ATEX directive and IEC 60079 requirements:
a) Product Type certification issued by an Ex notified body.
b) EC declarations of conformity by
i) the manufacturers of individual items and
ii) the package Supplier responsible for the installation / assembly.
c) Hazardous Area Schedule. A list of all items installed that includes required details in
project format.
d) Hazardous Area Equipment - Installation Report documenting the initial inspection,
required by IEC 60079-17 performed by the Supplier.

SUPPLIER shall provide a copy of the Pre-FAT test logs.


SUPPLIER shall be responsible for recording all FAT results. This includes a punch list of items to
be completed before the package is accepted and shipped. SUPPLIER shall certify in writing that
the factory test is satisfactorily completed with all errors corrected and all documents updated.
The following activities shall be included in the FAT:
Visual check of hardware inventory, cabinet and panel layouts and wiring vs. approved
design drawings.
For instruments not connected to a Supplier PLC, those instruments shall be checked for
continuity back to junction boxes.
For instruments not connected to a Supplier PLC, calibration reports shall be provided
showing SUPPLIER has checked for proper calibration and operation.
If possible, for instruments connected to a Supplier PLC, the instruments shall be powered
and process shall be simulated to show proper calibration of instrument and proper
configuration in the control system (this includes stroking valves from the control system).
For Supplier PLCs, whether PLC or other, the following activities shall be included:
Check system response times
Check system configuration loading
Check application program loading
Check proper takeover modes of redundant components
Check system diagnostic features
Demonstrate proper system operation at power up/power down/momentary power failure
and power switchover set point and function
Check system alarms
Perform 100% check of all I/O, control configuration, and responses of outputs to
simulated inputs
Demonstrate correct function of all peripherals including any fiber optic components
Demonstrate proper data highway configuration. Test plan to be submitted for
SUPPLIERs approval.
Mark all corrections or changes to SUPPLIER documentation to reflect as-shipped status.
Verified Cause & Effects diagrams functionality
5.14 FAT Conclusion
SUPPLIER shall submit to OWNER/PURCHASER, test reports to document the results of the FAT.
This FAT is a major contract hold point. The equipment cannot be shipped to the field until
OWNER/PURCHASER approves the results of the test.
Once OWNER/PURCHASER has approved the results of the FAT, the SUPPLIER shall schedule
all hardware to ship unless otherwise agreed to in writing.
SUPPLIER shall draft and issue all changes to documentation as a result of the FAT.
5.15 SAT
The SAT shall consist of the following activities (as a minimum) to be performed by the SUPPLIER
(SUPPLIER may recommend additional activities based on experience, and some activities may
be omitted where Supplier PLCs are not provided):
Verify supplier provided instruments and panels are installed properly
Verify field terminated signal, power and ground cables are terminated properly to supplier
equipment
Perform general inspection of all supplier instruments and systems
Power the system and perform diagnostics
Verify operator interfaces and other peripherals operate properly
Assist with the verification of communication highways to third party devices
Verify inputs and outputs are being properly manipulated in the system
Option: Assist with loop check of inputs and outputs
Option: Assist with check of shutdown logic functions to verify outputs react properly to input
conditions
SUPPLIER shall submit a project specific SAT procedure for approval six weeks prior to package
shipment.
SUPPLIER shall provide with quotation a schedule of field service rates for the two options listed

above, when SUPPLIER provides a control system.


SUPPLIER shall be responsible for recording all SAT procedures and results, as well as punch list
items.

9.2 Factory Acceptance Test


All testing shall be identified within an Inspection & Test Plan.
A schedule of tests to demonstrate compliance with this Specification and the main
package specification shall be provided. It shall include as a minimum the following
tests:
a) A visual inspection shall be made to ensure that good workmanship and practices
have been maintained throughout fabrication and assembly
b) A quantitative check shall be made to ensure that all items, in specified quantities are
present according to the purchase order and packing list.
c) Insulation / Megger Test of all wiring
d) All fuses and circuit breakers shall be checked for correct voltage and
current rating.
e) The electrical system shall be given a functional test to ensure total system operation.
It is the intent of this test to prove the proper interaction of all control and safety devices.
f) All interlockable safety devices and fail safe functions shall be tested.
g) Whenever the unit is shipped in more than one piece, it shall be fully
assembled and the Vendor shall ensure testing with all components
assembled.
5.17 Documentation
ALL FINAL INSTRUMENT/CONTROL DOCUMENTATION ON CD.
Prepare and submit documents in electronic media such as AutoCAD or MS Excel or other spread
sheet program as needed to mount, connect and troubleshoot the instrumentation including
instrument locations, vessel trim details, control room equipment layout and details, control panel
layouts, installation details, logic diagrams, schematics, loop diagrams, and junction box drawings.
Provide instrument drawings required to provide field power, locate the field signals and junction
boxes, run conduit or tray and connect wiring or tubing.
Identify power requirements including loads, breaker settings and type of power (UPS
requirements, etc.) via a table for all instruments requiring power.
Include documents for inline, custom and unusual instruments to OWNER/PURCHASER for
approval and as final certified drawings.
The drawings shall identify conformance with the requirements, dimensions for connections,
instrument type and manufacturer, proper application, location of equipment including instruments
and junction boxes, and interconnection diagrams with terminal numbers assigned. Emphasize
safety considerations such as protection of personnel, capital equipment and the environment.
Provide control narratives for regulatory controls, sequence controls, alarm and trip lists, and
logic/shutdown controls, whether or not these controls are implemented in the Seller or
OWNER/PURCHASERs control system. Provide Cause and Effect diagrams for shutdown logic.
Provide complete tag listing with Seller control system register location of all data that is to be read
by the PCS or written to the Seller control system by the PCS.
Provide all software loaded into PLCs, PCs, and any other electronic media. This includes, but is
not limited to, operating systems, graphic programs, logic programs, printer drivers, etc. Provide
copy of application programs created for control of the equipment.
Provide a copy of all software licenses.
Provide maintenance manuals for all instruments. Documents shall include the following:
Include all the "packaged" equipment dimensional information
Depict piping, valves and instruments for the operation of the package unit
Include item numbers assigned by OWNER/PURCHASER for equipment and instruments
Identify size, type and description of each item and process and utility connection to
OWNER/PURCHASER piping

Locate instruments, junction and terminal boxes, panels and connections to piping, vessels and
machines on general arrangement drawings in plan and elevation views
Show instrument air tubing and piping and valves
Provide an instrument list complete with type, manufacturer, model number and description for
each instrument and instrument valve to be supplied by the Seller
Include copies of control valve, safety relief valve, thermowell vibration and flow element
calculations
Include completed ISA S20 format data sheets for each instrument provided.
Include parts lists and list of recommended spares for instruments as defined in the Purchase
Documents.
Include instrumentation utility requirement schedule for power, cooling water, instrument air,
nitrogen, etc.
Document instrument removal and reinstallation procedure where required for shipping
Include copy of all configured applications (i.e. ladder logic, function block logic, graphics, etc.)
Include copy of certified test results for instruments, identified by instrument tag number (i.e. PSV
set pressure tests, valve seat leakage tests, transmitter calibration test, etc.)

5.0 PACKAGE COMPLETION AND TESTING


5.1 General
Prior to despatch all equipment shall be tested in accordance with the main equipment specification
and specified design codes. The packaging completion and testing requirements are covered below.
5.2 Pressure Testing
5.2.1 All fabricated piping spools shall be individually pressure tested in accordance with
the appropriate system design pressure and design code requirements. The assembled
systems shall be leak tested. Vulnerable equipment and instrumentation may be isolated
or removed for this activity. Test pressures shall be maintained for a sufficient period (not
less than 30 minutes) to permit complete inspection unless otherwise directed by design
code or specification.
5.2.2 All equipment and assembled systems shall be fully drained and dried to remove all traces of the
test medium. Water used for hydrostatic testing of stainless steel components shall have a chloride
content of less than 30 ppm and suitably inhibited.
5.3 System Cleaning
5.3.1 All equipment components and piping spools shall be cleaned by appropriate means prior to
package assembly. Stainless steel pipe spools shall be pickled and passivated. Carbon steel lines in
gas or clean services shall be de-scaled by pickling.
5.3.2 Following package assembly, all piping systems shall be flushed to meet a cleanliness criterion
specified by the supplier. Equipment and instrumentation may be isolated or removed for this activity.
Typically, equipment bearings will be by-passed. After flushing, the system shall be drained and
completely dried ready for putting into service or testing. The system cleaning and drying shall be
repeated after testing. Preservation for transportation and storage shall be applied to the clean and
dry system. Vulnerable instrumentation and equipment may be removed from the skid and packed
separately for transportation. Open ends and connections must be sealed and protected against
ingress of moisture and debris.
5.4 Instrument Calibration and Setting
5.4.1 All package instrumentation shall be check-calibrated and correctly set in accordance with the
Suppliers instrument schedule during the package assembly. The Suppliers instrument check-

calibration and settings records shall be retained by the supplier with copies included within the
package certification dossier along with the instrument Suppliers original calibration certification.
5.4.2 Instrument systems shall be connected as far as possible to simulate field
operation. Field inputs shall be simulated by appropriate switches, variable voltage or
current generators. Serial interfaces shall be tested using PCs utilising link specific
software. Field outputs shall be simulated by utilising pilot lights, milliammeters,
solenoids, etc. All simulators shall be fully wired up before testing commences. The tests
shall demonstrate that the equipment functions as intended.
Lifting Equipment Test
All lifting equipment supplied shall be subject to proof load/functional testing and be certified by a
recognised independent competent authority acceptable to the Purchaser. The devices shall be
uniquely identified with serial numbers and the Safe Working Load (SWL) for traceability back to the
certification. Functional testing of the fully assembled lifting system shall include but not limited to
lifting, lowering and traversing the rated load over its required length of travel in accordance with
approved procedures.
5.6 Electrical Testing
Electrical wiring and equipment shall be tested in accordance with the applicable NEMA & IEEE
Standard. Tests shall include wiring continuity; function tests to prove proper operation of controls,
alarms and protective devices; insulation and earth continuity tests.
6.0 MECHANICAL HANDLING
6.1 General
6.1.1 For routine maintenance and breakdown, the supplier shall provide a mechanical handling plan
for the package. This may be part of the general arrangement drawing. Mechanical handling shall
besingle man, or 110 lb. (50 kg), if access is provided for two men. In addition, mechanical handling
shall be provided if the lift is complicated or complex. The plan shall show runway beams, pad-eyes
etc, and include the rating of runway beams, pad-eyes, hoists and minimum hook heights and
withdrawal space requirements.
6.1.2 For equipment items not accessible by an external mechanical handling system, such as
equipment within the skid limits, the supplier shall supply a system. The system shall be designed to
transport the equipment to a laydown area. This may be outside the package skid limits.
6.1.3 Special lifting frames, spreader beams and other attachments that are required for
maintenance removal of some items of major equipment, e.g., rotors, pump cartridges,
etc, shall be supplied by the equipment supplier. Any special tools required for
maintenance shall also be supplied by the equipment supplier.